Design and assembly methodology for reducing bridging in bonding electronic components to pads connected to vias

ABSTRACT

An apparatus, comprising a substrate having a surface, comprising one or more solder pads, each having a center and connected to a via, each via having a center; positioned relative to the surface such that at least one of the one or more solder pad centers is offset from the connecting via center and an area of the at least one of the one or more solder pads overlaps an area of the connecting via.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates to the field of microchip assembly and in particular to connecting a die-substrate having a solder ball array to a substrate having a solder land array.

[0003] 2. Discussion of Related Art

[0004] The ever-increasing density improvements in silicon can be more fully exploited with corresponding wiring density improvements in chip carriers. Challenges to increased wire density have been met with ball grid array packaging designs. However, as the number of balls per unit area has increased, such as with C4 flip-chip designs, so have the routing problems. FIG. 1A illustrates a via-to-bonding pad design that is in the shape of a “dog bone”. The dog bone design has the solder land (bonding pad) distinctly separate from the via and connected with routing. Along with the need to route each bonding pad (pad) to each via in the dog bone design, there is also the increased difficulty of routing other circuitry around the “dog bones”. These routing problems can be reduced by designing with a via centered within the bonding pad (“via in pad” or VIP). FIG. 1B illustrates the pad centered on the via. VIP can free a number of routing channels and reduce the layer count but will also increase bridging caused by voids formed within the soldered balls. Solder ball bridging with the VIP design has been seen in up to 50% of product assembled in a high volume factory.

[0005] FIGS. 1C-1E illustrate how bridging problems occur with via in pad designs on a substrate such as a printed circuit board (PCB). Bridging problems are a result of gas expansion from one or more vias into one or more mating solder balls of a die-substrate at an elevated temperature point in assembly. FIG. 1C illustrates how the problem begins when the solder ball, centered over the pad and therefore over the via hole, contacts the pad/via, seals the via opening along with any gas within. FIG. 1D illustrates how, during a reflow operation, the sealed via gas is unable to vent and expands into the solder ball as the solder begins to liquefy. FIG. 1E illustrates where, once the solder ball approaches a liquid state, the via gas can become encapsulated within the solder and continue to expand as temperature is increased. Via gas expansion has the effect of expanding the solder ball as if blowing up a balloon. The solder ball expansion can continue until it contacts an adjacent solder ball causing bridging to occur. The solder bridging problems discussed generally involve the use of eutectic solder in the solder ball. Eutectic solder will flow as a liquid during the reflow heating process.

[0006]FIG. 1F illustrates another bridging problem where an adjacent (nonconnected) solder ball flows to contact a via. This can occur when solder ball spacing is too close along with solder mask that is very narrow or missing. To minimize this condition, solder ball spacing can be increased or, as illustrated in FIG. 1G, caps placed over the vias on the substrate side contacted by the solder balls (primary side). These caps are placed on the substrate with solder mask material and constitute an additional process step. An increase in solder ball spacing can reduce solder ball density overall.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1A is an illustration of a dog bone design for bonding pads and vias;

[0008]FIG. 1B is an illustration of a via in pad design;

[0009]FIG. 1C is an illustration of solder balls contacting solder pads;

[0010]FIG. 1D is an illustration of via gas entering liquefied solder balls;

[0011]FIG. 1E is an illustration of expanding solder balls bridging;

[0012]FIG. 1F is an illustration of bridging of a non-connected solder ball;

[0013]FIG. 1G is an illustration of via capping;

[0014]FIG. 2A is an illustration of a via tangent to pad design;

[0015]FIG. 2B is an illustration of overlap of a via tangent to pad;

[0016]FIG. 3A is an illustration of a via across pad design;

[0017]FIG. 3B is an illustration of a via tangent to pad design;

[0018]FIG. 4A is an illustration of a top view of a substrate with via openings;

[0019]FIG. 4B is an illustration of a cross-section of the substrate with via openings;

[0020]FIG. 5A is an illustration of the top view of the substrate with copper pads and via opening;

[0021]FIG. 5B is an illustration of the cross-section of the substrate with copper pads and via openings;

[0022]FIG. 6A is an illustration of the top view of the substrate with a solder mask having openings over the copper pads and via openings;

[0023]FIG. 6B is an illustration of the cross-section of the substrate with the solder mask having openings over the copper pads and via openings;

[0024]FIG. 7A is an illustration of the top view of the substrate with a layer of solder coating the copper.

[0025]FIG. 7B is an illustration of the cross-section of the substrate with the layer of solder coating the copper.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0026] A structure and method for the placement, on a substrate surface, of a number of solder lands (pads) having areas that overlap onto a number of solder lined via openings (vias), is disclosed. The solder lands, while offset from the vias, maintain an overlapping area. Therefore an electrical connection between the solder land and the via is exists but a routing connection is not required.

[0027] The present invention provides an area of the solder land that is offset from an area of the solder lined via opening where some common area is maintained, that is, the two areas have some overlap. In an embodiment, the solder lands and vias may be on a substrate such as a printed circuit board (PCB). The solder lands and vias may be positioned in an array to connect with a mating solder ball array of a die-substrate.

[0028]FIGS. 2A & B illustrate a “via tangent to pad” (VTP) design. In an embodiment, the bonding pads 202 are circular having a diameter 204 where each bonding pad 202 area overlaps 203 with each via 206 area to be connected. In an embodiment, each bonding pad 202 can be positioned so that the pad diameter 204 is approximately tangent to the via opening (hole) diameter 208 it overlaps. This can be accomplished by a center-to-center spacing 210 between the bonding pads 202 and the vias 206 that is the sum of the bonding pad radius 212 and the via hole radius 214, producing the tangent. Closer center-to-center spacing 210 may be accomplished as long the overlap 203 still permits venting of gas from within the via 206 during solder reflow, i.e. the solder ball (not shown) does not completely seal off the via hole at a critical phase. The critical phase is a temperature point in reflow where sufficient gas must escape from the via, not to be encapsulated in the solder ball, and before liquid solder ball solder flows into the via hole 216.

[0029]FIG. 3A illustrates an embodiment of a “via across pad” (VAP) design. This embodiment provides a closer positioning 302 of the solder pad to the connecting via than the VTP design 303 as shown in FIG. 3B. However, the VTP design may have a solder pad-to-solder pad center-to-center distance 307 that is approximately the same as the VAP design. The via across pad design (FIG. 3A) still maintains enough offset for via gas venting but allows for a closer packing of the via 312 to the connecting solder pad 314. With this embodiment, closer center-to-center 302 spacing between the solder pad center 304 and the via center 306 can increase the distance 308 between a non-connecting solder ball 310 and via 312, increase masking thicknesses between solder pads, and therefore reduce the possibility of a solder ball bridging to a non-connecting via. As a result, a process step of placing caps on the vias at the primary side (FIG. 1E) of the PCB can be eliminated. Capping vias could still be accomplished on the opposite (secondary) side since this is generally done for many vias on a PCB to eliminate the possibility of a solder leak. In addition, an increased distance between solder pads can allow for easier routing between solder balls and solder pads.

[0030]FIGS. 4A & B through FIGS. 7A & B illustrate an embodiment of a method to process a substrate and produce pads that overlap their connecting vias as with the via tangent to pad or the via across pad designs. Processing of the present invention begins, as FIGS. 4A & B illustrate, with a PCB substrate 402 having via openings 404 where the via openings 404 have deposited within, a solder coating 406 over a copper lining 409. The via openings 404 can run through the PCB substrate 402 and can be connected to a number of copper layers 407 and 408 on both sides of the PCB substrate 402. FIGS. 5A & B illustrate the results of a patterning operation where a photoresist coating (not shown) is applied to both copper surfaces 511 and 512 of the PCB substrate 502. The photoresist is developed to a pattern and the undeveloped photoresist areas removed with a solvent wash. Next, the copper layers 507 and 508 are etched to the pattern where the etching removes copper. A result can be that copper pads 514 and even copper edges 516 around via openings 506 are formed on one substrate surface 511. Elsewhere on the copper layers 507 and 508, other copper circuitry 518, including routing, may be created from the photoresist and etch processes. FIGS. 6A & B illustrate the application of a solder masks 622 and 624 that coat both sides 611 and 612 of the substrate 601. Prior to coating the solder masks 622 and 624, a photoresist coating (not shown) may be applied. The photoresist coating, can be pattern exposed and solvent washed to provide locations of photoresist coating around the via openings 604 and the pads 606. The solder mask 622 may be deposited by a process that applies the solder mask 622 to the substrate surface 611 except at the designated locations where the photoresist coating remains, e.g. over the vias 506 and at locations for solder pads 614. Alternatively, a solder mask stencil can be used. A second solder mask can coat the entire substrate opposite surface 624. Openings in the second solder mask 264 may be constructed as needed. FIGS. 7A & B illustrate the results of a wave soldering operation that can add a thin coating of solder 710 over the exposed surface of each copper pad 702 and via edge 704 of the substrate 703. The solder 710 will not adhere to solder mask material 722 and 724.

[0031] The bonding pad diameters and the via hole diameters are determined by the size of the corresponding solder balls, e.g. BGA substrates or C4 flip chip technologies, that connect to the bonding pads. In an embodiment using a BGA substrate, the bonding pads could have a diameter of approximately 0.30″, the via hole diameter could be approximately 0.010″, and the via outer diameter (OD) of the solder lining could be approximately 0.020-0.025″. Therefore, to produce the via tangent to pad (VTP) configuration, the center-to-center spacing would be approximately 0.025-0.0275″. With a via across pad (VAP) design, the centerto-center distance could be approximately 0.015″ for a bonding pad that is approximately 0.030″ in diameter and a via OD of approximately 0.020-0.025″. In this case, the pad position, relative to the connecting via, would be such that the pad diameter would cross through the connecting via hole center (FIG. 3A). However, even closer arrangements (not shown) between the pad and the connecting via are possible as long as via gas will not vent into the softening solder ball sufficient to cause solder ball bridging to an adjacent solder ball.

[0032] Bonding pads are typically round for convenience and positioned in an array. However, it is not necessary to have round bonding pads or bonding pads placed in an array, to practice the present invention. The present invention can be used with any bonding pad shape. It is only necessary to have overlap to provide the density of vias chosen in the design, the desired spacing between adjacent solder balls, while maintaining a sufficient offset between the via hole and the connecting solder ball to allow venting until the critical phase has passed, i.e. enough gas has vented and/or the heated solder ball has flowed without entraining any gas. Therefore, the offset dimension (as characterized by the center-to-center spacing) will vary with the solder ball size, the type of solder used, and the spacing provided between via holes. To maximize the density of vias, the offset bonding pads may be aligned in the any direction that meets the density required to mate with the die-substrate solder balls.

Appendix A

[0033] William E. Alford, Reg. No. 37,764; Farzad E. Amini, Reg. No. 42,261; William Thomas Babbitt, Reg. No. 39,591; Carol F. Barry, Reg. No. 41,600; Jordan Michael Becker, Reg. No. 39,602; Lisa N. Benado, Reg. No. 39,995; Bradley J. Bereznak, Reg. No. 33,474; Michael A. Bernadicou, Reg. No. 35,934; Roger W. Blakely, Jr., Reg. No. 25,831; R. Alan Burnett, Reg. No. 46,149; Gregory D. Caldwell, Reg. No. 39,926; Andrew C. Chen, Reg. No. 43,544; Thomas M. Coester, Reg. No. 39,637; Donna Jo Coningsby, Reg. No. 41,684; Florin Corie, Reg. No. 46,244; Dennis M. deGuzman, Reg. No. 41,702; Stephen M. De Klerk, Reg. No. 46,503; Michael Anthony DeSanctis, Reg. No. 39,957; Daniel M. De Vos, Reg. No. 37,813; Sanjeet Dutta, Reg. No. 46,145; Matthew C. Fagan, Reg. No. 37,542; Tarek N. Fahmi, Reg. No. 41,402; George Fountain, Reg. No. 37,374; James Y. Go, Reg. No. 40,621; James A. Henry, Reg. No. 41,064; Libby N. Ho, Reg. No. 46,774; Willmore F. Holbrow III, Reg. No. 41,845; Sheryl Sue Holloway, Reg. No. 37,850; George W Hoover II, Reg. No. 32,992; Eric S. Hyman, Reg. No. 30,139; William W. Kidd, Reg. No. 31,772; Sang Hui Kim, Reg. No. 40,450; Walter T. Kim, Reg. No. 42,731; Eric T. King, Reg. No. 44,188; George Brian Leavell, Reg. No. 45,436; Kurt P. Leyendecker, Reg. No. 42,799; Gordon R. Lindeen III, Reg. No. 33,192; Jan Carol Little, Reg. No. 41,181; Robert G. Litts, Reg. No. 46,876; Joseph Lutz, Reg. No. 43,765; Michael J. Mallie, Reg. No. 36,591; Andre L. Marais, under 37 C.F.R. §10.9(b); Paul A. Mendonsa, Reg. No. 42,879; Clive D. Menezes, Reg. No. 45,493; Chun M. Ng, Reg. No. 36,878; Thien T. Nguyen, Reg. No. 43,835; Thinh V. Nguyen, Reg. No. 42,034; Dennis A. Nicholls, Reg. No. 42,036; Robert B. O'Rourke, Reg. No. 46,972; Daniel E. Ovanezian, Reg. No. 41,236; Kenneth B. Paley, Reg. No. 38,989; Gregg A. Peacock, Reg. No. 45,001; Marina Portnova, Reg. No. 45,750; William F. Ryann, Reg. 44,313; James H. Salter, Reg. No. 35,668; William W. Schaal, Reg. No. 39,018; James C. Scheller, Reg. No. 31,195; Jeffrey Sam Smith, Reg. No. 39,377; Maria McCormack Sobrino, Reg. No. 31,639; Stanley W. Sokoloff, Reg. No. 25,128; Judith A. Szepesi, Reg. No. 39,393; Vincent P. Tassinari, Reg. No. 42,179; Edwin H. Taylor, Reg. No. 25,129; John F. Travis, Reg. No. 43,203; Joseph A. Twarowski, Reg. No. 42,191; Tom Van Zandt, Reg. No. 43,219; Lester J. Vincent, Reg. No. 31,460; Glenn E. Von Tersch, Reg. No. 41,364; John Patrick Ward, Reg. No. 40,216; Mark L. Watson, Reg. No. 46,322; Thomas C. Webster, Reg. No. 46,154; and Norman Zafman, Reg. No. 26,250; my patent attorneys, and Firasat Ali, Reg. No. 45,715; Justin M. Dillon, Reg. No. 42,486; Thomas S. Ferrill, Reg. No. 42,532; and Raul Martinez, Reg. No. 46,904, my patent agents, of BLAKELY, SOKOLOFF, TAYLOR & ZAFMAN LLP, with offices located at 12400 Wilshire Boulevard, 7th Floor, Los Angeles, Calif. 90025, telephone (310) 207-3800, and Alan K. Aldous, Reg. No. 31,905; Edward R. Brake, Reg. No. 37,784; Ben Burge, Reg. No. 42,372; Jeffrey S. Draeger, Reg. No. 41,000; Cynthia Thomas Faatz, Reg No. 39,973; John N. Greaves, Reg. No. 40,362; Seth Z. Kalson, Reg. No. 40,670; David J. Kaplan, Reg. No. 41,105; Peter Lam, Reg. No. 44,855; Charles A. Mirho, Reg. No. 41,199; Leo V. Novakoski, Reg. No. 37,198; Thomas C. Reynolds, Reg. No. 32,488; Kenneth M. Seddon, Reg. No. 43,105; Mark Seeley, Reg. No. 32,299; Steven P. Skabrat, Reg. No. 36,279; Howard A. Skaist, Reg. No. 36,008; Gene I. Su, Reg. No. 45,140; Calvin E. Wells, Reg. No. P43,256, Raymond J. Werner, Reg. No. 34,752; Robert G. Winkle, Reg. No. 37,474; Steven D. Yates, Reg. No. 42,242; and Charles K. Young, Reg. No. 39,435; my patent attorneys, of INTEL CORPORATION; and James R. Thein, Reg. No. 31,710, my patent attorney with full power of substitution and revocation, to prosecute this application and to transact all business in the Patent and Trademark Office connected herewith.

Appendix B Title 37, Code of Federal Regulations, Section 1.56 Duty to Disclose Information Material to Patentability

[0034] (a) A patent by its very nature is affected with a public interest. The public interest is best served, and the most effective patent examination occurs when, at the time an application is being examined, the Office is aware of and evaluates the teachings of all information material to patentability. Each individual associated with the filing and prosecution of a patent application has a duty of candor and good faith in dealing with the Office, which includes a duty to disclose to the Office all information known to that individual to be material to patentability as defined in this section. The duty to disclosure information exists with respect to each pending claim until the claim is cancelled or withdrawn from consideration, or the application becomes abandoned. Information material to the patentability of a claim that is cancelled or withdrawn from consideration need not be submitted if the information is not material to the patentability of any claim remaining under consideration in the application. There is no duty to submit information which is not material to the patentability of any existing claim. The duty to disclosure all information known to be material to patentability is deemed to be satisfied if all information known to be material to patentability of any claim cissued in a patent was cited by the Office or submitted to the Office in the manner prescribed by §§1.97(b)-(d) and 1.98. However, no patent will be granted on an application in connection with which fraud on the Office was practiced or attempted or the duty of disclosure was violated through bad faith or intentional misconduct. The Office encourages applicants to carefully examine:

[0035] (1) Prior art cited in search reports of a foreign patent office in a counterpart application, and

[0036] (2) The closest information over which individuals associated with the filing or prosecution of a patent application believe any pending claim patentably defines, to make sure that any material information contained therein is disclosed to the Office.

[0037] (b) Under this section, information is material to patentability when it is not cumulative to information already of record or being made or record in the application, and

[0038] (1) It establishes, by itself or in combination with other information, a prima facie case of unpatentability of a claim; or

[0039] (2) It refutes, or is inconsistent with, a position the applicant takes in:

[0040] (i) Opposing an argument of unpatentability relied on by the Office, or

[0041] (ii) Asserting an argument of patentability.

[0042] A prima facie case of unpatentability is established when the information compels a conclusion that a claim is unpatentable under the preponderance of evidence, burden-of-proof standard, giving each term in the claim its broadest reasonable construction consistent with the specification, and before any consideration is given to evidence which may be submitted in an attempt to establish a contrary conclusion of patentability.

[0043] (c) Individuals associated with the filing or prosecution of a patent application within the meaning of this section are:

[0044] (1) Each inventor named in the application;

[0045] (2) Each attorney or agent who prepares or prosecutes the application; and

[0046] (3) Every other person who is substantively involved in the preparation or prosecution of the application and who is associated with the inventor, with the assignee or with anyone to whom there is an obligation to assign the application.

[0047] (d) Individuals other than the attorney, agent or inventor may comply with this section by disclosing information to the attorney, agent, or inventor. 

We claim:
 1. An apparatus, comprising: a substrate having a surface, comprising: one or more solder pads, each having a center and connected to; a via, each via having a center; positioned relative to the surface such that at least one of the one or more solder pad centers is offset from the connecting via center and an area of the at least one of the one or more solder pads overlaps an area of the connecting via.
 2. The apparatus of claim 1, further comprising: each of the one or more solder pads having a diameter; each via having a hole diameter; such that the hole diameters are approximately tangent to the overlapping solder pad diameters.
 3. The apparatus of claim 1, wherein the one or more solder pads are positioned in an array.
 4. The apparatus of claim 3, wherein the connecting vias are positioned in an array.
 5. The apparatus of claim 4, wherein only one of the one or more solder pads overlaps each of the vias.
 6. An assembly, comprising: a die-substrate having an array of solder balls; a second substrate comprising: an array of solder pads, offset from an array of vias, such that an area of each solder pad overlaps a portion of one of the array of vias and the die-substrate is connected to the second substrate with the solder ball array soldered to the solder pad array.
 7. The apparatus of claim 6, wherein the die-substrate is a ball grid array package.
 8. The apparatus of claim 6, wherein the die-substrate is a C4 flip chip.
 9. A method comprising: obtaining a substrate surface comprising: vias, and one or more copper layers; screening at least one of the one or more copper layers to provide an array of solder pads that are offset from an array of connecting via openings and where each solder pad in the array overlaps with a via opening on the substrate surface.
 10. The method of claim 9, further comprising: overlapping the solder pad locations includes forming a diameter defining each solder pad where the diameter is tangent to a hole diameter for each connecting via.
 11. The method of claim 9, further comprising: overlapping the solder pad locations includes forming a diameter defining each solder pad where the diameter passes through a center of each connecting via.
 12. The method of claim 11, further comprising: obtaining a die-substrate having a solder ball array; and attaching the die-substrate to the substrate by connecting the solder ball array to the solder pad array.
 13. An apparatus, comprising: a substrate having a surface; means for offsetting one or more solder pads with one or more vias on the substrate surface without using routing.
 14. The apparatus of claim 13, wherein the solder pads and the vias are positioned in an array.
 15. The apparatus of claim 14, further comprising: means for connecting a die-substrate having a ball grid array to the substrate having the solder pad array such that, essentially, no voids are formed within the solder connections. 